Structural Component System

ABSTRACT

A structural component system which in some embodiments comprises at least one substantially planar component having a corrugated cross-section, a surface with substantially parallel channels, and a length measured substantially parallel to said channels, a first component coupled in layers with a second component to create a primary system assembly, and a primary system assembly coupled in layers with other primary system assemblies and components.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) from earlier filed U.S. Provisional Application Ser. No. 61/783,581, filed Mar. 14, 2013, the entirety of which is incorporated herein by reference.

BACKGROUND

1. Technical Field

The present system relates to the field of construction materials, particularly prefabricated or site-assembled decking sections.

2. Background

Conventional metal decks are capable of covering spans in the range of 10 to 15 feet, while specialized deep metal decks can cover spans in the 20 to 30-foot range. Slabs can offer greater spanning capability. For example, pre-stressed hollow concrete core slabs can typically span 20 to 40 feet. Typical waffle slabs can span 20 to 30 feet, but those with added depth and weight can span approximately 50 feet.

“Voided biaxial decks” (e.g., Bubbledeck or Cobiax) can span up to approximately 50 feet (60-feet if post-tensioned). Non-composite, one-way action, constant cross-section, prefabricated roof decks (e.g., Super Versa-Dek), which are comprised of two specific deck types that are mechanically connected to each other between node points, can span approximately 30 feet for roof loading.

However, these existing systems present several drawbacks. First, they offer limited control on cross-section variation along the span and therefore cannot be optimized for longer spans. Next, they require that utilities are located outside of the deck (typically below the deck), thus resulting in the necessity of providing a separate ceiling space and enclosure. Third, these existing systems result in basically flat top and bottom surfaces and cannot produce articulated surfaces or curved surfaces.

In addition some methods require additional shoring. Standard metal decking requires construction shoring for longer spans, while waffle-slab construction can require extensive formwork and shoring. Voided biaxial decks can demand extensive field labor for rebar placement, as well as additional shoring.

With a conventional metal deck, span length is a limiting factor. Moreover, since thin sheet metals are susceptible to plate buckling and reduced capacity, the sections must be thickened and deepened to achieve longer spans. Therefore, manufacturers would need to produce and build an inventory of decking with multiple section depths and of varying gages. Contractors have to bear the additional expense of transporting heavier materials to construction sites.

Although capable of greater spans than conventional metal decking, pre-stressed hollow concrete core slabs require a specialized fabrication facility and process, which can be time-consuming. Transporting these slabs to a job site also presents a challenge due to their weight and bulk. Once on-site, they are difficult to modify to accommodate building use or support utilities.

Typical naval and outer space structures are constructed by welding solid-plate elements together to form a surface skin. The weight of these elements requires reinforcement with frequent internal compression framing and/or external tension rings. In addition, these structures often require structural redundancy (e.g., double-hulled construction) and ductility to withstand unexpected collision forces. In such applications, there are clear advantages to using limited basic shapes that can be easily transported, assembled, and modified in the field.

What is needed is a simple system for creating custom metal decking on-site and on-demand.

SUMMARY

The present system provides a system of components that can be efficiently combined to create desired structural members, including supporting beams.

BRIEF DESCRIPTION OF THE DRAWINGS

Further details of the present system are explained with the help of the attached drawings in which:

FIG. 1 depicts a perspective view of one embodiment of the basic system component of the present system.

FIG. 2 a depicts a perspective view of one embodiment of a primary assembly of the present system.

FIG. 2 b depicts a side cross-sectional view of the embodiment shown in FIG. 2 a used in conjunction with flooring or other board.

FIG. 2 c depicts a side elevation view of the embodiment shown in FIG. 2 a used in conjunction with flooring or other board.

FIG. 2 d depicts a side cross-sectional view of the embodiment shown in FIG. 2 a used in conjunction with a concrete surface.

FIG. 2 e depicts a side elevation view of the embodiment shown in FIG. 2 a used in conjunction with a concrete surface.

FIG. 3 a depicts a perspective view of one embodiment of a secondary assembly of the present system.

FIG. 3 b depicts a perspective view of another embodiment of a secondary assembly of the present system in which the base components and/or primary assemblies are in a staggered formation.

FIG. 3 c depicts a side cross-sectional view of the embodiment shown in FIG. 3 a or 3 b used in conjunction with flooring or other board.

FIG. 3 d depicts a side elevation view of the embodiment shown in FIG. 3 c used in conjunction with flooring or other board.

FIG. 3 e depicts a side cross-sectional view of the embodiment shown in FIG. 3 a or 3 b used in conjunction with a concrete surface.

FIG. 3 f depicts a side elevation view of the embodiment shown in FIG. 3 e used in conjunction with a concrete surface.

FIG. 3 g depicts a side cross-sectional view of the embodiment shown in FIG. 3 a or 3 b used in conjunction with concrete on the top and bottom surfaces.

FIG. 3 h depicts a side elevation view of the embodiment shown in FIG. 3 g used in conjunction with concrete on the top and bottom surfaces.

FIG. 3 i depicts a side cross-sectional view of the embodiment shown in FIG. 3 a or 3 b used in conjunction with flooring or other board and a staggered configuration of secondary assemblies.

FIG. 3 j depicts a side elevation view of the embodiment shown in FIG. 3 i used in conjunction with flooring or other board and a staggered configuration of secondary assemblies.

FIG. 4 a depicts a perspective view of one embodiment of a secondary assembly of the present system used in conjunction with cellular decking on the bottom surface.

FIG. 4 b depicts a perspective view of one embodiment of a secondary assembly of the present system used with varying lengths of basic system components in conjunction with cellular decking on the bottom surface.

FIG. 4 c depicts a side cross-sectional view of the embodiment shown in FIG. 4 a or 4 b used in conjunction with flooring or other board and cellular decking.

FIG. 4 d depicts a side elevation view of the embodiment shown in FIG. 4 c used in conjunction with flooring or other board and cellular decking.

FIG. 4 e depicts a side cross-sectional view of the embodiment shown in FIG. 4 a or 4 b used in conjunction with concrete and cellular decking.

FIG. 4 f depicts a side elevation view of the embodiment shown in FIG. 4 e-used in conjunction with concrete and cellular decking.

FIG. 5 a depicts a perspective view of one embodiment of a secondary assembly of the present system having webs placed in between the basic components of the present system.

FIG. 5 b depicts a perspective view of one embodiment of a secondary assembly of the present system having webs placed in between the basic components of the present system with varying length of basic system components.

FIG. 5 c depicts a side cross-sectional view of the embodiment shown in FIG. 5 a or 5 b at full length component region used in conjunction with flooring.

FIG. 5 d depicts a side elevation view of the embodiment shown in FIG. 5 c-used in conjunction with flooring.

FIG. 5 e depicts a side cross-sectional view of the embodiment shown in FIG. 5 a or 5 b at full length component region used in conjunction with a concrete surface.

FIG. 5 f depicts a side elevation view of the embodiment shown in FIG. 5 e used in conjunction with a concrete surface.

FIG. 5 g depicts a side cross-sectional view of the embodiment shown in FIG. 5 a or 5 b at full length component region used in conjunction with a concrete surface and concrete soffit.

FIG. 5 h depicts a side elevation view of the embodiment shown in FIG. 5 g used in conjunction with a concrete surface and concrete soffit.

FIG. 6 a depicts a perspective view of one embodiment of a secondary assembly of the present system in which the basic components of the present system can be arranged orthogonally.

FIG. 6 b depicts a side cross-sectional view of the embodiment shown in FIG. 6 a used in conjunction with flooring and cellular decking.

FIG. 6 c depicts a side elevation view of the embodiment shown in FIG. 6 a used in conjunction with flooring and cellular decking.

FIG. 6 d depicts a side cross-sectional view of the embodiment shown in FIG. 6 a used in conjunction with a concrete surface and cellular decking.

FIG. 6 e depicts a side elevation view of the embodiment shown in FIG. 6 a used in conjunction with a concrete surface and cellular decking.

FIG. 7 a depicts a perspective view of one embodiment of a secondary assembly of the present system in which the basic components of the present system can be arranged orthogonally and with spaces in between.

FIG. 7 b depicts a side cross-sectional view of the embodiment shown in FIG. 7 a used in conjunction with flooring and cellular decking.

FIG. 7 c depicts a side elevation view of the embodiment shown in FIG. 7 a used in conjunction with flooring and cellular decking.

FIG. 8 a depicts a perspective view of another embodiment of a secondary assembly of the present system.

FIG. 8 b depicts a side cross-sectional view of the embodiment shown in FIG. 8 a used in conjunction with flooring or other board and cellular decking.

FIG. 8 c depicts a side elevation view of the embodiment shown in FIG. 8 a used in conjunction with flooring or other board and cellular decking.

FIG. 8 d depicts a side cross-sectional view of the embodiment shown in FIG. 8 a used in conjunction with a concrete surface or other board and cellular decking.

FIG. 8 e depicts a side elevation view of the embodiment shown in FIG. 8 a used in conjunction with a concrete surface or other board and cellular decking.

FIG. 8 f depicts a side cross-sectional view of the embodiment shown in FIG. 8 a used in conjunction with a concrete surface and concrete soffit.

FIG. 8 g depicts a side elevation view of the embodiment shown in FIG. 8 a used in conjunction with a concrete surface and concrete soffit.

FIG. 8 h depicts a side cross-sectional view of the embodiment shown in FIG. 8 a used in conjunction with a concrete surface and concrete soffit to create a cambered member.

FIG. 8 i depicts a side elevation view of the embodiment shown in FIG. 8 a used in conjunction with a concrete surface and concrete soffit to create a cambered member.

FIG. 9 a depicts a perspective view of another embodiment of a secondary assembly of the present system.

FIG. 9 b depicts a side cross-sectional view of the embodiment shown in FIG. 9 a used in conjunction with flooring or other board and cellular decking.

FIG. 9 c depicts a side elevation view of the embodiment shown in FIG. 9 a used in conjunction with flooring or other board and cellular decking.

FIG. 9 d depicts a side cross-sectional view of the embodiment shown in FIG. 9 a used in conjunction with a concrete surface and concrete soffit.

FIG. 9 e depicts a side elevation view of the embodiment shown in FIG. 9 a used in conjunction with a concrete surface and concrete soffit.

FIG. 10 a depicts a perspective view of another embodiment of a secondary assembly of the present system in which primary assemblies of the present system can be arranged orthogonally and with spaces in between.

FIG. 10 b depicts a side cross-sectional view of the embodiment shown in FIG. 10 a used in conjunction with solar panels.

FIG. 10 c depicts a side elevation view of the embodiment shown in FIG. 10 a used in conjunction with solar panels

FIG. 11 a depicts a perspective view of an embodiment of the present system used in conjunction with frame supports to create curved structures.

FIG. 11 b depicts a side cross-sectional view of the embodiment shown in FIG. 11 a.

FIG. 11 c depicts a side elevation view of the embodiment shown in FIG. 11 a.

FIG. 12 a depicts a perspective view of an embodiment of the present system used in conjunction with frame supports to create tubular structures.

FIG. 12 b depicts a side cross-sectional view of the embodiment shown in FIG. 12 a.

FIG. 12 c depicts a side elevation view of the embodiment shown in FIG. 12 a.

FIG. 13 a depicts a perspective view of an embodiment of the present system used in conjunction with frame supports to create tubular structures.

FIG. 13 b depicts a side cross-sectional view of the embodiment shown in FIG. 13 a.

FIG. 13 c depicts a side elevation view of the embodiment shown in FIG. 13 a.

FIG. 14 a depicts a front view of an embodiment of the present system in use as a wall member having varied cross-sectional and side elevation profiles.

FIG. 14 b depicts a top cross-sectional view of the embodiment shown in FIG. 14 a with interior cells filled with an additional material.

FIG. 14 c depicts a top cross-sectional view of another embodiment of the present system.

FIG. 14 d depicts a side elevation view of the embodiment shown in FIG. 14 c.

FIG. 14 e depicts a top cross-sectional view of an embodiment of the present system used in conjunction with a concrete surface in use as a wall member.

FIG. 14 f depicts a side elevation view of the embodiment shown in FIG. 14 e.

FIG. 14 g depicts a top cross-sectional view of an embodiment of the present system used in conjunction with concrete surfaces in use as a wall member.

FIG. 14 h depicts a side elevation view of the embodiment shown in FIG. 14 g.

FIG. 14 i depicts a top cross-sectional view of an embodiment of a secondary assembly of the present system having web members in use as a wall member.

FIG. 14 j depicts a side elevation view of the embodiment shown in FIG. 14 i.

FIG. 15 a-i depict various types of shear stiffener members that can be used in conjunction with embodiments of the present system.

DETAILED DESCRIPTION

FIG. 1 depicts a perspective view of one embodiment of a basic system component 102. As shown in FIG. 1, a basic system component 102 can be a substantially planar member with a corrugated cross-section, having a series of substantially parallel bends 104. In some embodiments, substantially parallel bends 104 can alternate between approximately 60-degrees and approximately 120-degrees to form a series of adjacent channels 106 having substantially semi-hexagonal cross-sections for a basic system component 102. However, in other embodiments, substantially parallel bends 104 can form channels 106 having substantially semicircular, sinusoidal, triangular, rectangular, or any other known and/or convenient cross-sectional geometry. In some embodiments, a basic system component 102 can be fabricated from steel, but in other embodiments can be made from aluminum, alloy, composite, or any other known and/or convenient material. In the embodiment shown in FIG. 1, a basic system component 102 can have a substantially rectangular geometry having a length l and a width w, where l denotes the dimension substantially parallel to bends 104 and channels 106 of a basic system component 102, and w denotes the dimension substantially perpendicular to bends 104 and channels 106 of a basic system component 102. However, in other embodiments, a basic system component 102 can have any other known and/or convenient geometry or dimensions.

FIG. 2 a depicts a perspective view of one embodiment of a primary assembly 202. As shown in FIG. 2 a, at least two basic system components 102 can be stacked and oriented with substantially parallel bends 104 and channels 106 aligned to form tube sections 203 having substantially hexagonal cross-sections. In such embodiments, basic system components 102 can be connected at adjacent surfaces with fasteners 204, which can be screws, bolts, rivets, locking tabs, or any other known and/or convenient system. As shown in FIG. 2 a, a group of fasteners 204 can be aligned substantially parallel to tube sections 203, but in other embodiments can be arranged in any other known and/or convenient configuration. In other embodiments, basic components 102 can be joined via welding, adhesive, or any other known and/or convenient method.

In some embodiments, as shown in FIGS. 2 b and 2 c, at least one primary assembly 202 can be used in conjunction with flooring 206 placed on the top surface of a primary assembly 202, wherein at least one primary assembly 202 can support flooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of a primary assembly 202 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. In some embodiments, as shown in FIG. 2 c, at least one support member 208 can be located on the bottom surface of and substantially along an edge of a primary assembly 202, and substantially perpendicular to the longitudinal axis of tube sections 203. In some embodiments, a support member 208 can be an I-beam, but in other embodiments, can be a beam with any other known and/or convenient cross-sectional geometry.

In some embodiments, as shown in FIGS. 2 d and 2 e, at least one primary assembly 202 can be used in conjunction with a concrete surface 210 adjacent to the top surface of a primary assembly 202, wherein at least one primary assembly 202 can support a concrete surface 210. In some embodiments of the present system, a “poured” material can also be considered “cast.” In some embodiments, a concrete surface 210 can be poured or cast in place directly onto at least one primary assembly 202. In some embodiments, as shown in FIG. 2 e, at least one support member 208 can be located on the bottom surface of and substantially along an edge of a primary assembly 202, and substantially perpendicular to tube sections 203. In some embodiments, a support member 208 can be an I-beam, but in other embodiments, can be a beam with any other known and/or convenient cross-sectional geometry.

FIG. 3 a depicts a perspective view of an embodiment of a secondary system assembly 302, wherein at least two primary assemblies 202 can be connected such that their bends 104 and channels 106 are substantially parallel. As shown in FIG. 3 a, at least a pair of secondary system assemblies 202 can be stacked and oriented with substantially parallel bends 104 and channels 106 aligned to form additional tube sections 203 having substantially hexagonal cross-sections between secondary system assemblies 302. In such embodiments, secondary system assemblies 302 can be connected at adjacent surfaces with fasteners 204, which can be screws, bolts, rivets, locking tabs, or any other known and/or convenient system. As shown in FIG. 3 a, a group of fasteners 204 can be aligned substantially parallel to tube sections 203, but in other embodiments can be arranged in any other known and/or convenient configuration. In other embodiments, secondary system assemblies 202 can be joined via welding, adhesive, or any other known and/or convenient method.

In some embodiments, as shown in FIG. 3 b, basic system components 102 and/or primary assemblies 202 can be of varied lengths to create various staggered-profile secondary assemblies 302. In such embodiments, the length of a secondary system assembly 302 can vary with the depth of a secondary system assembly 302. In some embodiments, at least two primary assemblies 202 of the same width can be connected such that a secondary assembly 302 has a uniform width, as seen in the frontal view of FIG. 3 c. FIG. 3 d depicts the embodiment of FIG. 3 c in profile view. In this embodiment, basic system components 102 can be of varying lengths and arranged from longest length to shortest length from top to bottom. As shown in FIG. 3 b, each basic system component 102 can also be beveled at its ends to any known and or convenient taper. As shown in FIG. 3 d, length can decrease substantially symmetrically with respect to the midpoint of the length of basic system components 102.

As shown in FIG. 3 c and FIG. 3 d, flooring 206 can be placed on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support flooring 206. In some embodiments, as shown in FIGS. 3 c and 3 e, a secondary assembly 302 can have a maximum depth substantially equal to the depth of two primary assemblies 202, but in other embodiments can have any other known and/or convenient depth. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of a secondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. In other embodiments, as shown in FIGS. 3 e and 3 f, at least one secondary assembly 302 can be used in conjunction with a concrete surface 210 adjacent to the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support a concrete surface 210. In some embodiments, a concrete surface 210 can be poured in place directly onto the top surface of a secondary assembly 202.

In some embodiments, as shown in FIGS. 3 d and 3 f, at least one support member 208 can be located on the bottom surface of and substantially along an edge of a topmost basic system component 102 (the longest basic system component 102 in the embodiment shown), and substantially perpendicular to tube sections 203. In some embodiments, a support member 208 can be an I-beam, but in other embodiments, can be a beam with any other known and/or convenient cross-sectional geometry.

In some embodiments, as shown in FIG. 3 g, at least three primary assemblies 202 of the same width can be connected such that a secondary assembly 302 has a uniform width, as seen in the frontal view of FIG. 3 g. In some embodiments, a secondary assembly 302 can have a maximum depth substantially equal to that of three primary assemblies 202, but in other embodiments can have any other known and/or convenient depth. FIG. 3 h depicts the embodiment of FIG. 3 g in profile view. In this embodiment, basic system components 102 can be of varying lengths and arranged from longest length to shortest length from top surface of a secondary assembly 302 to the center line, and then shortest to longest from the center to the bottom surface of a secondary assembly 302. As shown in FIG. 3 h, basic system component 102 length can change substantially symmetrically with respect to the midpoint of the length of basic system components 102.

In some embodiments, as shown in FIGS. 3 g and 3 h, a secondary assembly 302 can be used in conjunction with a concrete surface 210 on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support a concrete surface 210, and a concrete soffit 304 on the bottom surface of a secondary assembly 302. In some embodiments, a concrete surface 210 or a concrete soffit 304 can be poured in place directly adjacent to the top and bottom surfaces of a secondary assembly 302.

In some embodiments, as shown in FIG. 3 h, the top edge of a support member 208 can be located substantially along an edge of a secondary assembly 302, while the bottom edge can be attached to and/or anchored in a concrete soffit 304.

In some embodiments, at least two primary assemblies 202 of varying width can be connected such that a secondary assembly 302 has cross sections of varying width, as seen in the frontal view of FIG. 3 i. In some embodiments, each section of varying width can decrease in width from the top to the bottom and be configured in a symmetrical and/or regular pattern. However, in other embodiments, sections of varying width can be arranged in any known and/or convenient geometry or pattern. In some embodiments, a secondary assembly 302 can have a maximum depth substantially equal to the depth of 2.5 primary assemblies 202, but in other embodiments can have any other known and/or convenient depth. FIG. 3 j depicts the embodiment of FIG. 3 i in profile view. In this embodiment, basic system components 102 can be of varying lengths and arranged from longest length to shortest length from top to bottom. As shown in FIG. 3 i, length can decrease substantially symmetrically with respect to the midpoint of the length of basic system components 102.

As shown in FIG. 3 i and FIG. 3 j, flooring 206 can be placed on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support flooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of a secondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method.

In some embodiments, as shown in FIG. 3 j, at least one support member 208 can be located on the bottom surface of and substantially along an edge of a topmost basic system component 102 (the longest basic system component 102 in the embodiment shown), and substantially perpendicular to tube sections 203. In some embodiments, a support member 208 can be an I-beam, but in other embodiments, can be a beam with any other known and/or convenient cross-sectional geometry.

FIG. 4 a depicts a perspective view of an embodiment of a secondary system assembly 302, such as that depicted in FIG. 3 a, used in conjunction with cellular decking 402 on the bottom surface of a secondary system assembly 302. In some embodiments, as shown in FIG. 4 b, basic system components 102 and/or primary assemblies 202 can be of varied lengths to create various staggered profile secondary assemblies 302. In some embodiments, at least two primary assemblies 202 of the same width can be connected such that a secondary assembly 302 has a uniform width, as seen in the frontal view of FIG. 4 c. FIG. 4 d depicts the embodiment of FIG. 4 c in profile view. In this embodiment, basic system components 102 can decrease in length from top to bottom, and then can have a bottommost basic system component 102 with a length less than or substantially equal to that of a topmost basic component 102, but greater than the length of the intermediate basic components 102. As shown in FIG. 4 d, length can decrease or increase substantially symmetrically with respect to the midpoint of the length of basic system components 102.

As shown in FIG. 4 c and FIG. 4 d, flooring 206 can be placed on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support flooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of a secondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. As shown in FIG. 4 c, the embodiment of FIG. 4 b can be used in conjunction with cellular decking 402 on the bottom surface of a secondary system assembly 302. In some embodiments, a secondary assembly 302 can be used to construct a fully decked region.

In some embodiments, as shown in FIG. 4 d, at least one support member 208 can be located on the bottom surface of and substantially along an edge of a topmost basic system component 102 (the longest basic system component 102 in the embodiment shown), and substantially perpendicular to tube sections 203. In some embodiments, a support member 208 can be an I-beam, but in other embodiments, can be a hollow structural tube, channel, angle, or beam with any other known and/or convenient cross-sectional geometry. In other embodiments, a support member 208 can be a metallic plate, such as a steel plate cast in a concrete beam. In some embodiments, cellular decking 402 can be connected to a support member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method.

In other embodiments, as shown in FIGS. 4 e and 4 f, at least one secondary assembly 302 can be used in conjunction with a concrete surface 210 adjacent to the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support a concrete surface 210. In some embodiments, a concrete surface 210 can be poured in place directly onto the top surface of a secondary assembly 202. Such embodiments can also be used in conjunction with cellular decking 402 on the bottom surface of a secondary system assembly 302.

In some embodiments, as shown in FIG. 4 f, at least one support member 208 can be located on the bottom surface of and substantially along an edge of a topmost basic system component 102 (the longest basic system component 102 in the embodiment shown), and substantially perpendicular to tube sections 203. In some embodiments, a support member 208 can be an I-beam, but in other embodiments, can be a hollow structural section, channel, angle, top or bottom chord of a truss, a straight or bent plate cast in a concrete beam or on a top face of a concrete walls, or a beam with any other known and/or convenient cross-sectional geometry.

FIG. 5 a depicts a perspective view of an embodiment of a primary system assembly 202, wherein a web member 502 can be placed at any known and/or convenient intervals between basic system components 102. As shown in FIG. 5 a, a pair of basic system components 102 can be stacked and oriented with substantially parallel bends 104 and channels 106 aligned such that the spacing between basic system components 102 can alternate substantially regularly between a maximum and minimum spacing, wherein a minimum spacing can be determined by the thickness of a web member 502. In some embodiments, a plurality of web members 502 can provide support and spacing in between basic system components 102. As shown in FIGS. 5 a, 5 b, 5 c, and 5 d, in such embodiments, a tubular conduit region 504 can be created between basic system components 102. In some embodiments, a tubular conduit region 504 can have dimensions of approximately 16 inches high and approximately 24 inches wide, and can have a maximum height in the range of approximately 10 inches to approximately at least 22 inches and a maximum width in the range of approximately 12 inches to approximately at least 36 inches. In some embodiments, larger widths may require intermediate support in in the tubular conduit region 504, depending on the loading and section properties of the deck.

In some embodiments, a web member 502 can be comprised of a pair of channel members 506. A pair of channel members 506 can be placed concave-out and substantially along the longitudinal edges of and between basic system components 102 to create a primary system assembly 202 having a tubular conduit region 504 between the first and second basic system components.

In such embodiments, basic system components 102 can be connected to web members 502 with fasteners 204, which can be screws, bolts, rivets, locking tabs, or any other known and/or convenient system. In other embodiments, basic components 102 can be joined to web members 502 via welding, adhesive, or any other known and/or convenient method. As shown in FIGS. 5 c, 5 e, and 5 f, access hatches 516 can be placed in a basic component 102 to facilitate placement of utilities in a conduit region 504.

As shown in the embodiment of FIG. 5 b, the basic components 102 can be of different lengths, with the upper basic component 102 being longer than the lower component 102. In other embodiments, this configuration can be reversed.

As shown in FIG. 5 c, the embodiment of a primary assembly 202 with web members 502 as shown in FIGS. 5 a and 5 b can be used in conjunction with flooring 206. Flooring 206 can be placed on the top surface of a primary assembly 202, wherein at least one primary assembly 202 can support flooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of a primary assembly 202 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method.

In other embodiments, as shown in FIGS. 5 e and 5 f, at least one primary assembly 202 with web members 502 can be used in conjunction with a concrete surface 210 adjacent to the top surface of a primary assembly 202, wherein at least one primary assembly 202 can support a concrete surface 210. In some embodiments, a concrete surface 210 can be poured in place directly onto the top surface of a primary assembly 202.

In some embodiments, as shown in FIGS. 5 d and 5 f, at least one support member 208 can be located on the bottom surface of and substantially along an edge of a topmost basic system component 102 (the longer of the two basic system components 102 in the embodiment shown), and substantially perpendicular to conduit regions 504. In some embodiments, a support member 208 can be an I-beam, but in other embodiments, can be a beam with any other known and/or convenient cross-sectional geometry.

In some embodiments, as shown in FIGS. 5 g and 5 h, a primary assembly 202 with web members 502 can be used in conjunction with a concrete surface 210 on the top surface of a primary assembly 202, wherein at least one primary assembly 202 can support a concrete surface 210, and a concrete soffit 304 on the bottom surface of a primary assembly 202. In some embodiments, a concrete surface 210 or a concrete soffit 304 can be poured in place directly adjacent to the top and bottom surfaces of a primary assembly 202.

In some embodiments having a concrete soffit 304, as shown in FIG. 5 h, the top edge of a support member 208 can be located substantially along an edge of a primary assembly 202, while the bottom edge can be anchored in a concrete soffit 304. In some embodiments, a support member can be an end support beam comprised of bent plates (angles) that can be embedded in a concrete fill that can be poured at the same time as a concrete surface 210 top of a metal deck.

In some embodiments, as shown in FIG. 5 g, a concrete soffit 304 or any other known and or convenient substrate comprised of a liquid material that subsequently hardens into a solid state can be poured into any known and/or convenient form. A plurality of primary system assemblies 202 can be aligned substantially laterally adjacent to each other and substantially horizontally on the substrate such that there can be a gap between channel members 506 along the lateral sides of each primary system assembly 202 to create an interstitial longitudinal void 508 between channel members 506. In some embodiments, an interstitial longitudinal void 508 can have dimensions of approximately 16 inches high and approximately 24 inches wide, and can have a maximum height in the range of approximately 10 inches to approximately at least 22 inches and a maximum width in the range of approximately 12 inches to approximately at least 36 inches, and in some embodiments can have a width of approximately 25 inches. A top surface comprised of a pourable and subsequently hardening medium, such as a concrete surface 210, can be poured and can flow through the gaps to fill interstitial longitudinal voids 508 to form a continuous solid member connecting a top surface (concrete surface 210) and a substrate (concrete soffit 304).

In some embodiments, as shown in FIG. 5 g, and other embodiments, a plurality of lateral supports 512 and/or vertical supports 514 can be placed within conduit regions 504. In some embodiments, as shown in FIG. 5 g, if concrete topping is poured separately in each deck segment, there can be a cold joint 510 between segments when these are turned over and placed in position.

In some embodiments, a concrete surface 210 can be poured on top of a form, which can be on the ground, on shoring, or suspended from the bottom layer of a deck bottom layer. However, in other embodiments, the use of temporary formwork can be eliminated, which can result in a significant savings in time and material. In some embodiments, a concrete surface 210 can be poured as a topping on a deck, with deck acting as formwork, thus eliminating the need to use a temporary plywood formwork except for minimal formwork at the edges. In such embodiments, after a concrete surface has hardened, a deck with a concrete surface 210 can be turned over such that a concrete surface 210 can now be at the soffit 304 and the deck is exposed at the top surface. In such embodiments, a new layer of concrete can be poured on top to create a deck with a concrete surface adjacent to the top and bottom surfaces of decking, which can be constructed without any use of additional plywood temporary formwork.

Wall construction will be also similar and though plywood formwork may be used, it is advantageous to construct the wall horizontally on the ground as described above without any use of plywood formwork and then tilt it up into vertical position, similar to a tilt up concrete wall construction.

FIG. 6 a depicts a perspective view of an alternative embodiment of a secondary system assembly 302 comprised of substantially orthogonally stacked basic system components 102. In such embodiments, a primary assembly 202 can have a pair of basic system components 102 that can be stacked or layered such that the bends 104 and channels 106 of a basic component 102 can be oriented substantially orthogonally to the bends 104 and channels 106 of another basic component 102. In embodiments such as those shown in FIGS. 6 a, 6 b, 6 c, 6 d, and 6 e, each basic component 102 of a primary assembly 202, and, therefore, of a secondary assembly 302, can be of substantially equal dimensions and/or substantially congruent geometry. However, in other embodiments, each basic component 102 can be of different dimensions and/or geometries to create various configurations of secondary assemblies 302.

As shown in FIGS. 6 b-6 e, this embodiment can also be used in conjunction with flooring 206, cellular decking 402, and concrete 210 in any known and/or convenient combination. For example, as shown in FIG. 6 b and FIG. 6 c, flooring 206 can be placed on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support flooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of a secondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. As shown in FIGS. 6 a and 6 b, the embodiment of FIG. 6 b can be used in conjunction with cellular decking 402 on the bottom surface of a secondary system assembly 302 In some embodiments, cellular decking 402 can be connected to a support member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method.

In some embodiments, as shown in FIGS. 6 d and 6 e, a secondary assembly 302 can be used in conjunction with a concrete surface 210 on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support a concrete surface 210, and cellular decking 402 on the bottom surface of a secondary assembly 302. In some embodiments, cellular decking 402 can be connected to a support member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method. In other embodiments, a concrete soffit 304 can be used on the bottom surface of a secondary assembly 302. A concrete surface 210 or a concrete soffit 304 can be poured in place directly adjacent to the top and bottom surfaces, respectively, of a secondary assembly 302.

FIG. 7 a depicts a perspective view of another alternative embodiment of a secondary system assembly 302 comprised of substantially orthogonally stacked basic system components 102. In the embodiment shown in FIG. 7 a, a secondary assembly 302 can have a substantially rectangular geometry having a length l and a width w, where l denotes the dimension substantially parallel to bends 104 and channels 106 of a basic system component 102, and w denotes the dimension substantially perpendicular to bends 104 and channels 106 of a basic system component 102. However, in other embodiments, a secondary assembly 302 can have any other known and/or convenient geometry or dimensions. In some embodiments, as shown in FIG. 7 a, a primary assembly 202 can have one basic system component 102 that can be stacked or layered such that the bends 104 and channels 106 of a basic component 102 having a length l and a width w, This basic component 102 can be oriented substantially orthogonally to the bends 104 and channels 106 of at least one other basic component 102 that can have a length less than w and a width less than l. In such embodiments, basic system components 102 can be connected at adjacent surfaces with fasteners 204, which can be screws, bolts, rivets, locking tabs, or any other known and/or convenient system. In other embodiments, basic components 102 can be joined via welding, adhesive, or any other known and/or convenient method.

When connected to the basic component 102, these narrower basic components 102 can be spaced at any known and/or convenient interval, regular or irregular, such that when primary assemblies 202 are connected, conduit spaces 504 can be created between layers of primary assemblies 202. For example, in FIG. 7 a, narrower basic components 102 can have a width such that a plurality can fit within the length l of a larger basic component 102 and create multiple conduit spaces 504.

As shown in FIGS. 7 b and 7 c, this embodiment of a secondary assembly 302 can also be used in conjunction with flooring 206, cellular decking 402 in any known and/or convenient combination. For example, as shown in FIG. 7 b and FIG. 7 c, flooring 206 can be placed on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support flooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of a secondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. As shown in FIGS. 7 b and 7 c, the embodiment of FIG. 7 a can be used in conjunction with cellular decking 402 on the bottom surface of a secondary system assembly 302. In some embodiments, cellular decking 402 can be connected to a support member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method.

FIGS. 8-14 depict various other embodiments of the present system. In these embodiments, various widths and lengths of basic system components 102 can be combined to form a variety of cross-sections and support geometries. In some of these embodiments, additional features can be added for functional or aesthetic purposes.

FIG. 8 a depicts a perspective view of another embodiment of the present system. As shown in FIG. 8 b, primary assemblies 202 of varying width (as seen in FIG. 3 i) can be coupled to create a secondary assembly 302 having cross sections of varying width, as seen in the frontal view of FIG. 3 i. In some embodiments, each section of varying width can decrease and then increase in width from the top to the bottom to create longitudinal voids 802 substantially parallel to and oriented with substantially parallel bends 104 and channels 106. In some embodiments, primary assemblies 202 can be configured in a symmetrical and/or regular pattern, but in other embodiments can be arranged in any other known and/or convenient geometry.

As shown in FIG. 8 c, a side elevation view of the embodiment shown in FIG. 8 b, a plurality of secondary assemblies 202 can be placed at intervals between a pair of primary system components 102, creating a tertiary system assembly 804 having tubular voids 806 running substantially orthogonally to the longitudinal voids 802. In some embodiments, tubular voids 806 can have a substantially rectangular cross-section, but in other embodiments (i.e., those having primary assemblies 202 of varying length comprising secondary assemblies 302) can have any other known and/or convenient cross-sectional geometry.

FIGS. 8 b and 8 c also show this embodiment used in conjunction with flooring 206 and cellular decking 402. Flooring 206 can be placed on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support flooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of a secondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. In some embodiments, cellular decking 402 can be connected to a support member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method.

FIGS. 8 d and 8 e show this embodiment where at least one secondary assembly 302 can be used in conjunction with a concrete surface 210 adjacent to the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support a concrete surface 210. In some embodiments, a concrete surface 210 can be poured in place directly onto the top surface of a secondary assembly 202. Such embodiments can also be used in conjunction with cellular decking 402 on the bottom surface of a secondary system assembly 302.

In FIGS. 8 f and 8 g, this embodiment can be used in with a concrete surface 210 on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support a concrete surface 210, and a concrete soffit 304 on the bottom surface of a secondary assembly 302. In some embodiments, a concrete surface 210 or a concrete soffit 304 can be poured in place directly adjacent to the top and bottom surfaces of a secondary assembly 302.

FIGS. 8 h and 8 i also show the embodiment of FIGS. 8 f and 8 g used in conjunction with a concrete surface 210 and concrete soffit 304, but in which a tertiary system assembly 804 can be cambered.

FIG. 9 a depicts a perspective view of a tertiary system assembly 804. In some embodiments, a tertiary system assembly 804 can have a transverse void 902. In some embodiments, a transverse void 902 can have a width approximately less than one-third of the length of tertiary assembly 804, but in other embodiments can have any other known and/or convenient dimensions.

FIGS. 9 b and 9 c also show this embodiment used in conjunction with flooring 206 and cellular decking 402. Flooring 206 can be placed on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support flooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of a secondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. In some embodiments, cellular decking 402 can be connected to a support member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method. In some embodiments, as shown in FIG. 9 c, a tertiary system assembly 804 can be supported by bearing on the bottom surface, but in other embodiments can be used in conjunction with any known and/or convenient support method.

FIGS. 9 d and 9 e show this embodiment in use with a concrete surface 210 on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support a concrete surface 210, and a concrete soffit 304 on the bottom surface of a secondary assembly 302. In some embodiments, a concrete surface 210 or a concrete soffit 304 can be poured in place directly adjacent to the top and bottom surfaces of a secondary assembly 302.

As shown in FIG. 10 a, in some embodiments, configurations of the present system can be formed into edge beams 1002 that can support solar panels 1004, or any other known and/or convenient panel. In the embodiment shown in FIG. 10 a, primary assemblies 202 can have a substantially rectangular geometry with a length measured in a direction substantially parallel to and a width measured in a direction substantially perpendicular to channels 106. To form edge beams 1002, first primary assemblies 202 having a given length and width can be substantially orthogonally stacked and coupled with other secondary assemblies 202 having a length substantially equal to the width of first primary assemblies 202 and a width less than half of the measure of the length of first primary assemblies 202. As shown in FIGS. 10 a and 10 b, in some embodiments, second primary assemblies 202 can have a width less than one-third of the measure of the length of first primary assemblies 202 and be placed along the edges of a first primary assembly 202 to form edge beams 1002, but in other embodiments can have any other known and/or convenient geometry and/or dimensions.

As shown in FIG. 11 a, in some embodiments, the present system can be configured into arches or other types of curved geometries. FIG. 11 a depicts a perspective view of such an embodiment where a plurality of secondary assemblies 302 can be arranged and coupled along their longitudinal edges to create a curved construction. Such embodiments can be used in conjunction with cellular decking 402 as described in previous embodiments. Such embodiments can also be used in conjunction with flooring 206 as described in previous embodiments. Such embodiments can also be used in conjunction with concrete surfaces 210, flooring 206, and any other known and/or convenient materials. Framing 1102 can be added to provide additional support. In this and other embodiments, a foam polymer material 1104 can be added to the spaces within a structure to provide thermal or sound insulation, or, in applications where an embodiment is used against water, to protect against water infiltration and enhance flotation.

FIG. 11 b depicts a cross-sectional view of the embodiment in FIG. 11 a.

FIG. 11 c depicts a side elevation view of the embodiment in FIG. 11 b.

FIG. 12 a depicts another embodiment of the present system where a plurality of secondary assemblies 302 can be used to fabricate structures with a substantially closed polygonal cross-section. In the embodiment shown in FIG. 12 a, such structures can have a substantially hexagonal cross-sectional geometry, but in other embodiments can have any other known and/or convenient geometry. In such embodiments, an external tension ring 1202 can be added to provide further structural support. Such embodiments can also be used in conjunction with flooring 206 as described in previous embodiments. Such embodiments can also be used in conjunction with concrete surfaces 210, cellular decking 402, and any other known and/or convenient materials.

FIG. 12 b depicts a cross-sectional view of the embodiment in FIG. 12 a.

FIG. 12 c depicts a side elevation view of the embodiment in FIG. 12 b.

FIG. 13 a depicts an embodiment of the present system where a plurality of primary assemblies 202 can be configured to form an edge beam 1302. In the embodiment shown in FIG. 13 a, a first set of primary assemblies 202 can have a substantially rectangular geometry with a length measured in a direction substantially parallel to and a width measured in a direction substantially perpendicular to channels 106. To form edge beams 1302, a first set primary assemblies 202 having a given length and width can be stacked and coupled such that their channels 106 are substantially parallel and their edges are substantially flush with each other. These first primary assemblies 202 can be coupled with second primary assemblies 202 having a length substantially equal to the width of first primary assemblies 202 and a width less than half of the measure of the length of first primary assemblies 202. As shown in FIGS. 13 a and 13 b, in some embodiments, second primary assemblies 202 can have a width less than one-fifth of the measure of the length of first primary assemblies 202 and be placed along the edges of a set of first primary assemblies 202 to form edge beams 1302, but in other embodiments can have any other known and/or convenient geometry and/or dimensions. In this and other embodiments, a foam polymer material 1104 can be added to the spaces within a structure to provide thermal or sound insulation, or, in applications where an embodiment is used against water, to protect against water infiltration and enhance flotation.

FIGS. 13 b and 13 c also show this embodiment used in conjunction with flooring 206 and cellular decking 402. Flooring 206 can be placed on the top surface of a secondary assembly 302, wherein at least one secondary assembly 302 can support flooring 206. Flooring 206 can be plywood, composite, metal, or any other known and/or convenient material. Flooring 206 can be installed as “floating,” or connected to the top surface of a secondary assembly 302 by screws, bolts, rivets, locking tabs, or any other known and/or convenient fastening system, or via welding, adhesive, or any other known and/or convenient method. In some embodiments, cellular decking 402 can be connected to a support member 208 via welding, screws, welded studs, epoxy, or any other known and/or convenient method.

In addition, in this and other embodiments, larger sections of secondary assemblies 302 can be connected with a segment connector 1304.

FIG. 13 b depicts a cross-sectional view of the embodiment in FIG. 13 a.

FIG. 13 c depicts a side elevation view of the embodiment in FIG. 13 b.

FIG. 14 a depicts a front view of an embodiment of the present system in use as a wall member having varied cross-sectional and side elevation profiles. Some embodiments of the present system in use as a wall member can support axial loads, but in other embodiments can be non-load-bearing. As shown in FIG. 14 a, a secondary assembly 302 can be positioned such that substantially parallel channels 106 can be oriented substantially vertically to create a wall member. In some embodiments, fenestrations 1402 can be cut through a secondary assembly 302 to accommodate windows or any other know and/or convenient portal. As shown in FIG. 14 a, fenestrations 1402 can have a substantially square or rectangular geometry, but in other embodiments can have any other known and/or convenient geometry.

FIG. 14 b depicts a top view of the embodiment shown in FIG. 14 a. As shown in FIG. 14 b, primary assemblies 202 of varying width (as previously described in FIG. 3 i) can be coupled to create a secondary assembly 302 having cross sections of varying width. In some embodiments, each section of varying width can decrease and then increase in width from the top to the bottom to create longitudinal voids 802 substantially parallel to and oriented with substantially parallel bends 104 and channels 106. In some embodiments, primary assemblies 202 can be configured in a symmetrical and/or regular pattern, but in other embodiments can be arranged in any other known and/or convenient geometry. In some embodiments, foam polymer material 1104 can be added to the spaces within a structure to provide thermal or sound insulation or added strength. In other embodiments, granular, liquid or any other known and/or convenient substance can be added to the spaces within a structure to provide insulation or added strength. In some embodiments, this can increase the relative stiffness of the vertical members to the horizontal members in a structure, thereby achieving a preferred failure mechanism in which failure occurs in the horizontal elements before the vertical elements.

FIG. 14 c depicts a top cross-sectional view of another embodiment of the present system. In some embodiments, a plurality of basic system components 102 and/or primary assemblies 202 of varied widths can be coupled as previously described to create various staggered-cross-section secondary assemblies 302 for structural or aesthetic purposes. In some embodiments a cross-section can vary in a substantially regular, repeating pattern to create a wall member having regions of varying thicknesses, but in other embodiments can have any other known and/or geometry. In such embodiments, a wall member can be non-bearing.

FIG. 14 d depicts a side elevation view of the embodiment shown in FIG. 14 c. As shown in FIG. 14 d, a plurality of basic system components 102 and/or primary assemblies 202 of varied lengths can be coupled to create various staggered-profile secondary assemblies 302. In such embodiments, the length of a secondary system assembly 302 can vary with the depth of a secondary system assembly 302. In the embodiment shown in FIG. 14 d, a secondary system assembly 302 can have a side elevation profile with a region of maximum thickness substantially along the midline and tapering substantially symmetrically to a minimum thickness at the ends of a secondary assembly 302. However, in other embodiments, a side elevation profile can vary in with any other known and/or convenient configuration. Such embodiments can be used as non-bearing wall members in conjunction with a roof member 1404.

FIG. 14 e depicts a top cross-sectional view of an embodiment of a secondary assembly 302 of the present system (as previously described in FIG. 3 a) used in conjunction with a concrete surface 210 in use as a wall member. Such embodiments can be used as non-bearing wall members in conjunction with a roof member 1404. In such embodiments, a concrete surface 210 can be placed on one surface of a secondary assembly 302. In some embodiments, a concrete surface 210 can be poured in place directly adjacent to a surface of a secondary assembly 202.

FIG. 14 f depicts a side elevation view of the embodiment shown in FIG. 14 e. Such embodiments can be used as non-bearing wall members in conjunction with a roof member 1404, but in other embodiments can be a load-bearing wall member.

FIG. 14 g depicts a top cross-sectional view of an embodiment of the present system (as previously described in FIG. 3 h) used in conjunction with concrete surfaces 210 in use a wall member, which can be load-bearing. In some embodiments, a secondary assembly 302 can have a uniform width, but in other embodiments can have any other known and/or convenient cross-section.

FIG. 14 h depicts a side elevation view of the embodiment shown in FIG. 14 g. In this embodiment, basic system components 102 can be of varying lengths and arranged from longest length to shortest length from one surface of a secondary assembly 302 to the center line, and then shortest to longest from the center to the opposite surface of a secondary assembly 302. As shown in FIG. 14 h, basic system component 102 length can change substantially symmetrically with respect to the midpoint of the length of basic system components 102. Such embodiments can be used as bearing wall members to support a roof member 1404.

FIG. 14 i depicts a top cross-sectional view of an embodiment having webs placed in between the basic components of the present system (as previously described in FIG. 5 g) in use as a wall member, which can be load-bearing. In such embodiments, as shown in FIG. 14 i, a pair of basic system components 102 can be oriented with substantially parallel bends 104 and channels 106 substantially vertical and aligned such that the spacing between basic system components 102 can alternate substantially regularly between a maximum and minimum spacing, wherein a minimum spacing can be determined by the thickness of a web member 502. In some embodiments, a plurality of web members 502 can provide support and spacing in between basic system components 102.

In some embodiments, a web member 502 can be comprised of a pair of channel members 506. A pair of channel members 506 can be placed concave-out and substantially along the longitudinal edges of and between basic system components 102 to create a primary system assembly 202.

In some embodiments, as shown in FIG. 14 i, concrete surfaces 210 or any other known and or convenient substrate comprised of a liquid material that subsequently hardens into a solid state can be poured into any known and/or convenient form. A plurality of primary system assemblies 202 can be aligned substantially laterally adjacent to each other and substantially vertically such that there can be a gap between channel members 506 along the lateral sides of each primary system assembly 202 to create an interstitial longitudinal void 508 between channel members 506. In some embodiments, an interstitial longitudinal void 508 can measure approximately 16 inches along an axis substantially perpendicular to a wall, and approximately 24 inches along an axis substantially parallel to the wall dimension of a gap. A form can be placed adjacent to the exterior surfaces of a primary assembly 202 to create a first concrete surface 210 and a second concrete surface 210. A first surface 210 comprised of a pourable and subsequently hardening medium, such as a concrete, can be poured and can flow through the gaps to fill interstitial longitudinal voids 508 to form a continuous solid member connecting a first concrete surface 210 and a second concrete surface 210.

FIG. 14 j depicts a side elevation view of the embodiment shown in FIG. 14 i. Such embodiments can be used as wall members to support a roof member 1404.

FIGS. 15 a-15 i depict embodiments of the present system in use with various types of shear stiffener supports 1502. These can be end connections of secondary assemblies 302 shown in FIGS. 1-14. In some embodiments, shear stiffener supports 1502 can support high reactions at the ends of secondary assemblies 302 where such a deck can span a much longer distance than single conventional deck, and such decks can be prone to local plate buckling due to their thin sections. In some embodiments, shear stiffener supports 1502 can be a partial filling of an end region with concrete or other solids so as the deck does not buckle under high shear at ends. In other embodiments, shear stiffener supports 1502 can involve inserting sheet metal deck profiles at the ends (basically small lengths of similar decks nested in the main deck) to practically thicken the deck in the end region. In other embodiments, shear stiffener supports 1502 can include adding stiffeners at the end, which can be steel plates that are placed perpendicular to the main deck to stop the deck from buckling and thus increase its (bearing) shear capacity, but in other embodiments can be any other known and/or convenient structural member.

As depicted in FIG. 15 g, in some embodiments, support elements 1504 can be included at the underside of the decking. In some embodiments, the support elements 1504 can be “L” sections. However, in alternate embodiments, any other known convenient and/or desired section and/or built-up section can be used and/or the support elements 1504 can be absent.

As depicted in FIGS. 15 h-15 i, in some embodiments, support elements 1504 can be coupled with attachment elements 1506 and/or additional support elements 1508. In some embodiments the attachment elements 1506 can be studs attached to one or more of the support elements 1504 at regular and/or irregular intervals. However, in alternate embodiments the attachment elements can have any known and/or convenient geometry and/or location and/or can be absent.

As depicted in FIGS. 15 h-15 i, additional support elements 1508 can be selectively coupled with the support elements 1504. In the embodiments depicted in FIGS. 15 h-15 i, the additional support elements 1508 can be truss bars. However, in alternate embodiments the additional support elements 1508 can have any known, convenient and/or desired positioning and/or geometry and/or can be absent.

In operation, the support elements can act as temporary support structures during construction and/or can act as attachments for equipment that is adapted to lift decking into position during construction.

In use, the present system offers several advantages. First, only simple and light-weight deck sections need to be kept in a manufacturer's inventory and when needed, they can be rapidly combined into the required complex sections. The present system also offers variation in depth, solid portion width, steel gage and connection frequency, as well as concrete reinforcing along the span and perpendicular to span. This advantage, when combined with the light weight of the system, can enable it to cover longer spans than currently available systems and can reduce the need for intermediate support framing.

Spans can be increased and the shoring requirements and intermediate field beams can be eliminated. Moreover, with traditional metal deck systems there is often a need for separate end beams to support the reactions from the deck and transport them to the columns. However, with the present system, the ends of the decks can be detailed to form an integral beam when the concrete topping is poured in the field, which can eliminate the need for a separate supporting beam. In addition, the present system can reduce the need for construction shoring, since the metal deck that forms the soffit, top, and web of the combined section can have adequate strength and stiffness to support the construction loads for non-composite construction and also until the concrete hardens for composite construction.

In the present system, curved surfaces along the span and perpendicular to the span can be achieved, as well as flat finished surfaces at the top or soffit. Thus shallow barrel vault arches as well as shallow dome construction are possible. This can be advantageous for roofs due to the inherent strength of arch systems and the resulting efficiency of drainage systems for the roof. Further, articulated soffit or roof configurations can also be achieved if desired for aesthetic effects or functional reasons.

Another advantage of the present system is that it can facilitate utility placement in the structure. With the present system, large utilities can be accommodated within the structural depth of the deck. Moreover, the utilities can run in two perpendicular directions within the structural depth, and access to utility chases can be easily accommodated with hatches 516 placed in the top most and/or bottom most deck layers.

The present system also offers several advantages for the specialized construction of marine and outer-space structures. Compared to typical marine and/or outer-space structures which use solid plate elements for their skin structures, the proposed steel deck can provide reduction in total weight due to its more efficient use of material (structural depth) which can reduce the need for frequent internal compression framing and/or external tension rings. Moreover, the present system, due to its cellular structure, can have more redundancy, and ductility in the case of damage from unexpected impact and/or collision forces. Finally, filling the cells with light-weight foaming material can seal and provide buoyancy for naval structures.

When applied to outer-space structures, the system can be used as a two-way platform where it is not subject to any differential internal/external pressure, such as for a support structure for solar panels. Alternatively, for sealed inhabitable spaces that are subject to high differential pressures between the inside and outside, the deck can be formed into a cylindrical type structure with external tension rings placed as required. The first inner layer (e.g., a cellular deck) can form one sealing surface. The deck voids can additionally be filled with a lightweight foaming material and/or liquid sealant to provide additional sealing surfaces in case a small puncture occurs.

The present system can be used to create wall spans as well as decking spans. In creating wall spans, the present system can offer flexibility in designing walls with various cross-sections to withstand shear forces, compression loads, and any other known, unknown, constant, or variable forces.

Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the invention as described and hereinafter claimed is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims. 

What is claimed is:
 1. A structural component system, comprising: at least one substantially planar component having a corrugated cross-section, a surface with substantially parallel channels, and a length measured substantially parallel to said channels; a first component coupled in layers with a second component to create a primary system assembly; and a primary system assembly coupled in layers with other primary system assemblies and components.
 2. The system of claim 1, said components coupled such that said channels of each component are substantially parallel and a series of tubular regions are created by the coupling of said components.
 3. The system of claim 2, said primary system assemblies coupled such that the tubular regions of said primary assemblies are substantially parallel and an additional series of adjacent tubular regions are created between said layers of primary assemblies.
 4. The system of claim 3, the widths of said primary system assemblies varied to create longitudinal voids that are substantially parallel to the tubular regions of said primary assemblies within the thickness of a secondary system assembly.
 5. The system of claim 4, a plurality of secondary assemblies placed at intervals between a pair of components, creating a tertiary system assembly having tubular voids running orthogonally to the longitudinal voids.
 6. The system of claim 5, said tertiary assembly having a cambered configuration.
 7. The system of claim 3, the lengths of said primary system assemblies and components varied to create a non-uniform profile.
 8. The system of claim 7, the lengths of said primary system assemblies and components decreasing symmetrically along the vertical midline of a secondary assembly.
 9. The system of claim 7, the lengths of said primary system assemblies and components decreasing and increasing symmetrically along the vertical midline of a secondary assembly.
 10. The system of claim 1, said components coupled in layers such that said channels of adjacent components are substantially orthogonal.
 11. The system of claim 10, said layers of components alternating between a single component and a plurality of components having dimensions less than that of said component to create interstitial spaces between adjacent layers.
 12. The system of claim 2, said primary system assemblies coupled in layers such that the tubular regions of said primary assemblies are substantially orthogonal.
 13. The system of claim 12, said layers of primary system assemblies alternating between a single primary system assembly and a plurality of primary system assemblies having dimensions less than that of said single primary system assembly to create interstitial spaces between adjacent layers.
 14. The system of claim 3, a plurality of secondary system assemblies used in conjunction with a support frame to create curved structures.
 15. The system of claim 3, used in conjunction with additional construction materials selected from the group consisting of: concrete, flooring, cellular decking, channels, angles, fasteners, granular materials, and polymer foams.
 16. A structural component system, comprising: a substrate comprised of a pourable and subsequently hardening medium; a first substantially planar component and a second substantially planar component having a corrugated cross-section with a series of alternating minima and maxima that creates a surface with substantially parallel channels; a pair of channel members; said basic system components substantially vertically aligned such that said channels of each component are substantially parallel and the corrugation maxima points of a first component are substantially aligned with the minima points of a second component, and said pair of channel members placed concave-out and substantially along the longitudinal edges of and between said components to create a primary system assembly having a tubular void created by the first and second components, and a plurality of primary system assemblies aligned substantially laterally adjacent and substantially horizontally on the substrate such that there is a gap between the channel members along the lateral sides of each primary system assembly to create an interstitial longitudinal void between the channels; a top surface comprised of a pourable and subsequently hardening medium, said surface medium, when poured, flowing through said gaps to fill said interstitial longitudinal void and form a continuous solid member connecting said top surface and substrate.
 17. The system of claim 16, further comprising a plurality of supports placed in the substrate to elevate the lower surface of the secondary assemblies above the lower surface of the substrate.
 18. The system of claim 16, further comprising a plurality of lateral supports placed within said tubular voids.
 19. The system of claim 16, further comprising a plurality of vertical supports placed within said tubular voids.
 20. A structural component system, comprising: a substantially planar plywood form; a plurality of supports placed substantially perpendicular to the surface of the form; concrete poured onto the form; a plurality of first substantially planar components each having a corrugated cross-section with a series of alternating minima and maxima that creates a surface with substantially parallel channels placed on top of the concrete while aligned substantially laterally adjacent to each other and substantially horizontally on the substrate and resting on the plurality of supports; a pair of channel members placed concave-out and substantially along the longitudinal edges of a first component such that there is a gap between the channel members and forming an interstitial longitudinal void; a plurality of second components each having a corrugated cross-section with a series of alternating minima and maxima that creates a surface with substantially parallel channels substantially vertically aligned with said first component, such that said channels of each component are substantially parallel and the corrugation maxima points of a first component are substantially aligned with the minima points of a second component, with the longitudinal edges placed adjacent to the top edge of the channel members to create a primary system assembly having a tubular void created by the first and second components, a concrete surface poured over the plurality of second components, such that the concrete flows through said gaps to fill said interstitial longitudinal void and form a continuous solid member connecting said top surface and substrate. 